LED lamp strip and manufacturing process thereof

ABSTRACT

A process of manufacturing an LED lamp strip includes the steps of forming a plurality of through holes on an adhesive tape, mounting the adhesive tape to a top side of a scrollable lead frame, bonding a plurality of LED chips to the top side of the scrollable lead frame according to the positions of the through holes, packaging the LED chips respectively, and finally cutting the scrollable lead frame. In light of this, the LED lamp strip can be produced under the circumstances of low production cost and less production time.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to an LED (light emitting diode), and more particularly, to a process of manufacturing an LED lamp strip and the LED lamp strip.

2. Description of the Related Art

Referring to FIG. 1, in a conventional LED lamp strip 10, a plurality of LED packages 12 are mounted on the surface of a flexible circuit board 14 by surface mounted technology (SMT) and then a reflow process is applied to the flexible circuit board 14 and the LED packages 12 to allow the LED packages 12 to be securely soldered on the surface of the flexible circuit board 14. However, the high temperature resulting from the reflow process tends to bring about adverse effect on the LED packages 12.

Referring to FIG. 2, in another conventional LED lamp strip 20, a plurality of LED chips 22 are fixed on the surface of a support member 26 by an adhesive tape 24 and finally packaged separately. However, this conventional LED lamp strip 20 is formed of a plurality of the support members 26 connected with one another by soldering for required length. In this way, the production cost and time are increased.

SUMMARY OF THE INVENTION

The primary objective of the present invention is to provide an LED lamp, which can be manufactured conveniently at low cost.

The foregoing objective of the present invention is attained by the LED lamp composed of a support member, an adhesive tape, and a plurality of LED packages. The support member is a part cut from a scrollable lead frame. The adhesive tape is adhesively mounted to a top side of the support member and includes a plurality of through holes spaced from one another. Each of the LED packages extends through one of the through holes of the adhesive tape to be mounted to the top side of the support member.

The secondary objective of the present invention is to provide a manufacturing process of the LED lamp strip, which can decrease the product cost and time.

The foregoing objective of the present invention is attained by the manufacturing process of the LED lamp strip. The manufacturing process includes the steps of providing the scrollable lead frame, forming a plurality of the through holes spaced from one another on the adhesive tape, mounting the adhesive tape to a top side of the scrollable lead frame, adhesively mounting a plurality of LED chips to the top side of the scrollable lead frame according to the positions of the through holes, packaging the LED chips respectively to produce the LED packages, and finally cutting the scrollable lead frame to produce the LED lamp strip. In light of this, the present invention does not need the reflow process to avoid the high temperature of the reflow process applied to the LED packages. Besides, the lead frame can be cut as per required length to avoid multiple soldering.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a conventional LED lamp strip.

FIG. 2 is a top view of another conventional LED lamp strip.

FIGS. 3A-3E are flow charts in accordance with a preferred embodiment of the present invention.

FIG. 4 is an enlarged view of a part of the preferred embodiment of the present invention.

FIG. 5 is a sectional view of the preferred embodiment of the present invention, showing the assembly of the LED lamp strip.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

A manufacturing process of an LED lamp strip 30 in accordance with a first preferred embodiment of the present invention includes the following steps.

a) Provide a scrollable lead frame 32 defining a plurality of interconnected support sections 34 and a plurality of interconnected crop sections 36. As shown in FIG. 3A, a cutting line L is located between each two of the support sections 34, which are adjacent to each other. As shown in FIG. 4, each two of the crop sections 36 are connected in pair to two sides of the support section 34 separately.

b) Form a plurality of through holes 42 spaced from one another on an upper adhesive tape 40 to mark where LED chips 46 are to be adhesively mounted and where positive and negative electrodes are to be connected. And then mount the upper adhesive tape 40 to top sides of the support sections 34, as shown in FIG. 3B. Next, mount a lower adhesive tape 44 to bottom sides of the support sections 34, as shown in FIG. 3C.

c) Bond a plurality of the LED chips 46 to the top sides of the support sections 34 according to the through holes 42 by adhesive fillers separately. The lower adhesive tape 44 can prevent the adhesive fillers from leakage. Next, package each of the LED chips 46 to produce one LED package 48.

d) cut the crop sections 36 out of the lead frame 32 to enable the support section 34 to become a support member. Next, cut the lead frame 32 along the cutting line L for a required length. In this way, the LED lamp strip 30 is completed, as shown in FIG. 3E.

In light of the above steps, the LED lamp strip 30 is made based on the lead frame 32, so the reflow process can be skipped to prevent the high temperature of the reflow process from affecting the LED package 48. Besides, the lead frame 32 can be cut therefrom for a part of a desired length to avoid the multiple soldering process for lower production cost and less production time. On the other hand, the LED lamp strip 30 made based on the aforesaid manufacturing process includes one of the support members (the support section 34), the upper adhesive tape 40 bonded to the top side of the support member, the lower adhesive tape 44 bonded to the bottom side of the support member, and one of the LED packages 48 mounted to the top side of the support member and located in the through hole 42 of the upper adhesive tape 40, as shown in FIG. 3E. Before the follow-up assembly procedure, an insulated thermally-conductive adhesive tape 50 is bonded to a thermally-heating member 52. Next, the LED lamp strip 30 is bonded to the insulated thermally-conductive adhesive tape 50, as shown in FIG. 5. Finally, the positive and negative electrodes are connected with each other to complete the assembly.

Although the present invention has been described with respect to a specific preferred embodiment thereof, it is in no way limited to the specifics of the illustrated structures but changes and modifications may be made within the scope of the appended claims. 

What is claimed is:
 1. A process of manufacturing an LED lamp strip comprising steps of: a) providing a scrollable lead frame; b) forming a plurality of through holes spaced from one another on an adhesive tape and then mounting the adhesive tape to completely cover a top side of the lead frame excluding a crop section; c) bonding a plurality of LED chips to the top side of the lead frame according to positions of the through holes respectively and then package each of the LED chips to produce one LED package; and d) cutting the lead frame to produce the LED lamp strip.
 2. The process as defined in claim 1, wherein the step b) further comprises a sub-step of mounting another adhesive tape to a bottom side of the lead frame.
 3. The process as defined in claim 1, wherein the lead frame in the step a) defines at least one support section and at least two crop sections, the support section being adapted for mounting the adhesive tape in the step b), the at least two crop sections being connected with two sides of the support section; the two crop sections are cut out of the lead frame in the step d) to enable the support section to become a support member.
 4. The process as defined in claim 3, wherein the scrollable lead frame in the step a) defines a plurality of interconnected support sections, a plurality of interconnected crop sections, and a cutting line located between each two of the support sections, which are adjacent to each other; after the crop sections are cut in the step d), the lead frame is cut along the cutting line. 